Manufacturing method of layered core

ABSTRACT

When layering a no.  2  partial magnetic core lamination furnishing an axis inserted on one side of a magnetic pole extending inward from a partial yoke and a partial yoke lamination onto a no.  1  partial magnetic core lamination furnishing a circular hole partially opening to one side of a magnetic pole extending inward from a partial yoke and a partial yoke lamination, the no.  1  and no.  2  partial magnetic core laminations are connected to rotate freely.

BACKGROUND OF THE INVENTION

[0001] 1. Scope of the Invention

[0002] The invention concerns the manufacturing method of a layered core forming an electrical stationary part.

[0003] 2. Relevant Technology

[0004] The stationary core, in order to be operational and productive as a coil for a magnetic pole, is punched out in partitions of stationery core sheets, layering these, a partial magnetic pole core is formed and wire is wound on this partial magnetic pole core. Then, after winding, the partial magnetic pole cores are assembled into a circular shape and, connecting them, the stationery core is formed. By this method winding is easy but, in assembling the partial magnetic pole cores, a long time is required for connecting them.

[0005] For this reason, a method has been proposed recently whereby, in conjunction with punching out partial magnetic core sheets in a metal molding device, the sheets are connected by moving them freely back and forth. In this way assembly after winding is easily and effectively carried out. For example, as shown in FIGS. 7˜9, of the partial magnetic pole core sheets, there is a no. 1 partial magnetic pole sheet [80] and a no. 2 partial magnetic pole sheet [81]. No. 1 partial magnetic pole core sheet [80] forms a partial yoke part [83] furnished with caulking parts [82] assymetically opposite a pole part [84] and, together with this, on the pointed end which extends the partial yoke part [83], a connection [80 a] is formed having a concave part [85] on the upper side and a convex part [89] on the lower side. The no. 2 partial magnetic pole core sheet [81] layered with no. 1 partial magnetic pole core sheet [80] forms a partial yoke part [87] furnished with caulking parts [86] opposite the pole part [88] and assymetically in reverse to the no. partial magnetic pole core sheet [80] and, on the pointed of the side which extends the partial yoke part [87], a connection [81 a] is formed having a concave part [85] on the upper side and a convex part [89] on the lower side. By such construction, no. 2 partial magnetic pole core sheets [81] successively punched externally are layered onto no. 1 partial magnetic pole core sheets [80] which are punched externally forward and, together with interfitting the convex part [89] of the connector [81 a] of no. 2 partial magnetic pole core sheet [81] with the concave part [85] of the connector [80 a] of no. 1 partial magnetic pole core sheet [80]; by connecting no. 1 partial magnetic pole core sheet [80] and no. 2 partial magnetic pole core sheet [81] by caulking parts [82, 86] in the direction of the layering, the partial magnetic pole core sheets can be connected by moving them freely back and forth.

[0006] However, because the no. 1 partial magnetic core sheet [80] and the no. 2 partial magnetic core sheet [81] form partial yoke parts [83, 87] with each other in a reverse assymetric relation and these sheets are punched out and layered on top of each other, the layering process becomes complicated for each layering step because of the differing shapes of the partial yoke part [83] of the no. 1 partial magnetic pole core sheet [80] and the partial yoke part [87] of the no. 2 partial magnetic pole core sheet [81]. Also, the formation of the concave [85] and convex [89] parts of the connectors [80 a, 81 a], as shown in FIG. 9, make the punch [90] advance from its diameter onto the die [91] furnished with small holes and the concave [85] and convex [89] parts are formed on the upper side and lower side, respectively, of the partial yoke parts [83, 87]. In this case, if a thin metal laminate is being used, when constructing the no. 1 partial magnetic pole sheet [80] and no. 2 partial magnetic pole core sheet [81], it is difficult to stabilize the concave [85] and convex [89] parts and the instability of the movability of the connectors is a problem. The number [93] is a pressing plate which sandwiches the metal laminate [92] together with the die [91].

SUMMARY OF THE INVENTION

[0007] As the invention was made in view of such circumstances, its purpose is to offer the manufacturing method of a layered core which can be made from thin metal laminations with stable connections together with simply executing the layering and rotating connections of the partial magnetic core laminations.

[0008] In conformity with said purpose, the manufacturing method of the layered core relating to the invention alternately punches out several no. 1 partial magnetic core laminations which form no. 1 ring core laminations and several no. 2 partial magnetic core laminations which form no. 2 ring core laminations from a metal laminate. In the manufacturing method of the layered core which repeats this layering to the desired thickness, for said no. 1 partial magnetic core laminations, a connector is formed which connects with the upper side of said no. 2 partial magnetic core laminations on one side of a partial yoke on the outer circumference and a magnetic pole which extends from the said partial yoke inwards and for said no. 2 partial magnetic core laminations, a connector is formed which connects with the lower side of said no. 1 partial magnetic core laminations on one side of a partial yoke on the outer circumference and a magnetic pole which extends from said partial yoke inwards. Moreover, said connector formed on one side of the partial yoke of said no. 1 magnetic core laminations are formed as a partially open circular hole and the connector formed on one side of the partial yoke of said no. 2 partial magnetic core laminations forms an axis which is inserted into said circular hole formed on said no. 1 partial magnetic core laminations. When several no. 2 partial magnetic core laminations are fully extracted and layered onto several previously extracted no. 1 partial magnetic core laminations, said axis are bent and inserted into said circular holes; said no. 1 partial magnetic core laminations and no. 2 partial magnetic core laminations are connected in a free rotation.

[0009] The partial yokes of the no. 1 magnetic core laminations and the no. 2 magnetic core laminations are formed in an essentially symmetrical shape opposite the respective magnetic poles and only the connectors which are formed on one side of each no. 1 partial magnetic core lamination and the other side of no. 2 partial magnetic core lamination have an asymmetrical formation. For this reason, in the layering of the no. 1 partial magnetic core laminations and the no. 2 partial magnetic core laminations, each no. 1 lamination and each no. 2 lamination can be layered in order respectively as they are extracted and, in the layering process, layering of the no. 1 ring core laminations formed from several said no.1 partial magnetic core laminations and the no. 2 ring core laminations formed from several said no. 2 partial magnetic core laminations can be easily carried out.

[0010] Also, circular holes are furnished partly opening into the partial yoke of no. 1 partial magnetic core laminations, axis are furnished which are inserted into circular holes partly opening into the partial yoke of no. 2 partial magnetic core laminations, and the connections of no. 1 and no. 2 laminations are carried out by inserting the axis into the circular holes. For this reason, no. 1 partial magnetic core laminations and no. 2 partial magnetic core laminations can be connected easily in a free rotation. Further, as the shape of the connectors formed respectively on no. 1 and no. 2 laminations is simple, each laminate connection is made to the respective no. 1 lamination and no. 2 lamination.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is an oblique view of the layered core made by the manufacturing method of a layered care relating to the conditions of one embodiment of this invention.

[0012]FIG. 2 is a plane view of a no. 1 circular ring lamination which constitutes the same layered core.

[0013]FIG. 3 is a plane view of a no. 2 circular ring lamination which constitutes the same layered core.

[0014]FIG. 4 is a plane view of a connector of the same layered core.

[0015]FIG. 5 is a partial cross-sectional view of a connector of the same layered core.

[0016]FIG. 6 is a conceptual drawing showing the structure of a press station for the manufacture of a layered core.

[0017]FIG. 7 is a plane view of a no. 1 ring core lamination consituting a layered core relating to prior art.

[0018]FIG. 8 is a plane view of a no. 2 ring core lamination constituting a layered core relating to prior art.

[0019]

[0020]FIG. 9 is a descriptive drawing depicting the formation of the concave and convex parts of the connection of the layered core relating to prior art.

A BRIEF DESCRIPTION OF AN EMBODIMENT SITUATION

[0021] So, now referring to the accompanying drawings, we will describe an embodiment situation which concretizes the invention and explains it.

[0022] Here, FIG. 1 is an oblique view of the layered core made by the manufacturing method of a layered core relating to the conditions of one embodiment of this invention, FIG. 2 is a plane view of a no. 1 circular ring core lamination which constitutes the same layered core, FIG. 3 is a plane view of a no. 2 ring core lamination which constitutes the same layered core, FIG. 4 is a plane view of a connector of the same layered core, FIG. 5 is a partial cross-sectional view of a connector of the same layered core, and FIG. 6 is a conceptual drawing of a press station for the manufacture of a layered core.

[0023] As shown in FIG. 1, the layered core [10] applying the manufacturing method of a layered core relating to one embodiment situtation of the invention, being constructed by caulk layering no. 1 ring core laminations and no. 2 ring core laminations alternately using caulking parts [13] formed on the no. 1 ring core and no. 2 ring core linations respectively, is furnished with ring yokes [14] on the outer circumference and several (8 this embodiment) magnetic poles [15] projecting inwards from the ring yokes [14]. These will be described more specifically below.

[0024] As shown in FIG. 2 and 3, no. 1 ring core laminations [11] are formed by arranging several (8 in this embodiment) no. 1 partial magnetic core laminations [16] in a ring so that they are in contact with each other and no. 2 ring core laminations [12] are formed by arranging several (8 in this embodiment) no. 2 partial magnetic core laminations [17] in a ring so that they are in contact with each other.

[0025] As shown in FIG. 2, 3, and 4, on no. 1 partial magnetic core laminations [16] are formed partial yokes [18] on the outer circumference and magnetic poles [19] extending inwards from the partial yokes [18] and on one side of the partial yokes [18] a circular hole [20] is put which opens partially as a connector which connects with each no. 2 partial magnetic core lamination [17] forming a no. 2 ring core lamination [12] layered on top. Also, on no. 2 partial magnetic core laminations [17] are formed partial yokes [21] on the outer circumference and magnetic poles [22] extending inwards from the partial yokes [21] and on the other side of the partial yokes [21] an axis [24] is put which is a connector inserted into a circular hole [20] furnished on the no. 1 partial magnetic core lamination [16] forming a no. 1 ring core lamination [11] layered on the bottom. The axis [24] has a connecting piece [23] connected with the other side of the partial yoke [21] and an axial body [24 a].

[0026] Caulking parts [13] are fashioned in the center of the partial yokes [18, 21] and in the center of the contacts [19 a, 22] of the magnetic poles [19, 22] and split yokes [18, 21]. Here, the caulking parts [13] are of commonly known construction and one side may protrude and the other sink; the respective caulking parts [13] may be constructed so that the sinking and protrusion are joined on the surface and the back.

[0027] Also, the respective exteriors of the partial yokes [18] and magnetic poles [19] furnished on the no. 1 partial magnetic core laminations [16] are made essentially identical with the respective exteriors of the partial yokes [21] and magnetic poles [22] of the no. 2 partial magnetic core laminations [17].

[0028] As shown in FIG. 2 and 3, in the no. 1 ring core laminations [11] and no. 2 ring core laminations [12], for example, a no. 1 partial magnetic core lamination [26] not forming a circular hole [20] on one side of the no. 1 partial magnetic core lamination [16] and a no. 2 partial magnetic core lamination [27] not forming an axis [24] on the other side of a no. 2 partial magnetic core lamination [17]. The exteriors of these no. 1 partial magnetic core lamination [26] and no. 2 partial magnetic core lamination [27] are essentially identical with their respective no. 1 partial magnetic core laminations [16] and no. 2 partial magnetic core laminations [17]. The no. 1 partial magnetic core laminations [25, 26] contact each other at the cut line [29] and the no. 2 laminations [27, 28] at the cut line [30] respectively. Thus, strictly speaking, the no. 1 ring core lamination [11] is arranged to make contacts in a ring with the no. 1 partial magnetic core laminations [16, 25, 26] as shown in FIG. 2 and the no. 2 ring core lamination [12] is arrange to make contacts in a ring with the no. 2 partial magnetic core laminations [17, 27, 28]. The layered core [10] is produced such that no. 1 and no. 2 ring core laminations [11, 12] are caulk layered alternately to a prescribed thickness.

[0029] As shown in FIG. 4 and 5, into the circular hole [20] furnished on one side of the partial yoke [18] forming the no. 1 partial magnetic core lamination [16] an axial body [24 a] can be inserted by bending a connecting material the the axis [24] furnished on the other side of the partial yoke [21] of the no. 2 partial magnetic core lamination [17] layered on the no. 1 partial magnetic core lamination [16]. Due to this, the no. 1 laminations [16] and no. 2 laminations [17] can be easily connected to rotate freely. As shown in FIG. 4, a notch [31] on one side of the outer circumference of the partial yoke [18] which the circular hole [20] forms and a notch can be formed which is identical to the notch [31] on one side of the outer circumference of the partial yoke [21] not shown in the figure.

[0030] By means of the construction as above, ring yoke [14] can be constructed from the partial yokes [18, 21] magnetic pole [15] can be constructed from magnetic poles [19, 22] by layering a prescribed number of laminations of no. 1 ring core laminations [11] and no. 2 reing core laminations [12] alternately. Also, a layered core [10] can be produced from the partial layered core [32] equipped with one ring yoke [14] and magnetic pole [15] apiece, respectively.

[0031] From the cut lines [29, 30] on no. 1 ring core laminations [11] and no. 2 ring core laminations [12], as shown in FIG. 1, forms a cut line [33] in an identical corner position. as each no. 1 partial magnetic core lamination [16] and each no. 2 partial magnetic core lamination [17] are connected to rotate freely, the layered core [10] can be detached at the cut line [33]. Further, with the respective notches on the partial yokes [18, 21], after detaching widening is possible and the partial layered core [32] can be arranged in a stright line. Due to this, each magnetic pole can be open and winding is easy.

[0032] Next, we will describe the manufacuring method of the layered core relating to one embodiment situation of the invention.

[0033] In FIG. 6 we show a conceptual drawing of a press station [34] which produces the layered core [10]. The metal laminate [35] from which rotor core [38], no. 1, and no. 2 partial magnetic core laminations [16, 25, 26, 17, 27, 28, respectively] are punched out is conveyed to the press station [34] and a rotor core production area [36] is furnished on the upper flow side and a stator core production area [37] on down flow side by which the metal laminate [35] is conveyed.

[0034] Provided with a rotor core production area [36], several punching out stages continue forming the outer circumference of the rotor core lamination [38] in order and, provided with a stator core production area [37], several punching out stages continue forming each outer circumference of no. 1 and no. 2 partial magnetic core laminations [16, 25, 26, 17, 27, 28] in order. The metal laminate [35] is conveyed intermittently at a prescribed speed by the press action of the punching out stages at the same time provided by the rotor core [36] and the stator core [37].

[0035] For the metal laminate [35] conveyed to the rotor core production area [36], when passing through the rotor core production area [36], the outer circumference of the rotor core lamination [38] is formed in order and the final outer circumference punch of the rotor core lamination [38] is made into a punch and die not shown in the figure. The rotor core lamination [38] is punched into the die hole [39] and rotor core lamination [38] previously layered onto the receiving platform of a receiving cylinder not shown in the figure. Due to this, the rotor core is formed.

[0036] The metal laminate [35] of which the outer circumference punching of the rorot core lamination [38] is completed is conveyed to the stator core production area [37] and, when passing through the stator core production area [37], first the outer circumference of no. 1 partial magnetic core laminations [16, 25, 26] are formed in order and the final puch and die of the no. 1 partial magnetic core laminations [16, 25, 26] are made into a punch and die not shown in the figure. The no. 1 partial magnetic core lamination [16, 25, 26] are punched into die holes [40] exhibiting a ring to form the no. 1 ring core lamination [11] as shown in FIG. 2. This no. 1 ring core lamination [11] is placed on the receiving platform of a receiving cylinder not shown in the figure which freely advances into a die hole [40]. Then, the outer circumference of the no. 2 partial magnetic core laminations [17, 27, 28] are formed in order, the final outer circumference punch of the no. 2 partial magnetic core laminations [17, 27, 28] are made, these no. 2 partial magnetic core laminations [17, 27, 28] are punched into die holes [40] exhibiting a ring to form no. 2 ring core laminations [12] as shown in FIG. 3, and they are layered and caulked onto the no. 1 ring core lamination [11] already positioned on the receiving platform.

[0037] The caulk of no. 1 ring core laminations [11] and no. 2 ring core lamination [12] placed on the receiving platform and punched into the die hole [40] is interfit with the caulking parts [13] of each no. 1 partial magnetic lamination [16, 25, 26] and each no. 2 partial magnetic core lamination [17, 27, 28], respectively, by dropping into a die hole [40] and the addition of a load up and down from the receiving of a receiving cylinder not shown in the, figure at the time of the outer circumference punch not shown in the figure. Being provided with a protruberance pressing in contact with the axis [24] in the punch, the connector [23] provided on each no. 2 partial magnetic core lamination [17, 28] is bent and the axial body [24 a] is inserted into the circular holes [20] which are provided on the no. 1 partial magnetic core lamination [16, 25] layered below.

[0038] Due to this, with the no. 1 ring core laminations [11] and no. 2 ring core laminations [12] being able to connect in layers, each of the no. 1 [16, 25, 26] and no. 2 [17, 27, 28] partial magnetic core laminations can be connected to be freely rotating.

[0039] Then, on the no. 2 ring core lamination [12] caulk layered with the no. 1 ring core lamination [11] previously deposited in the die hole [40], together with the respective caulking as mentioned above layering no. 1 ring core laminations [11] with punched outer circumference and then no. 2 ring core laminations [12] with punched outer circumference, in the circular holes [20] provided on each of the no. 1 partial magnetic core laminations [16, 25] forming the caulk layered no. 1 ring core laminations [11] an axis [24] and connector [23], provided on each of the no. 2 partial magnetic core laminations [17, 28] forming a no. 2 ring core [12], are inserted by bending.

[0040] Thus, whenever a no. 2 ring core lamination [12] is layered onto a no. 1 ring core lamination [11], by the addition of a load up and down dropping the punch at the die hole [40], together with connecting the no. 1 ring core laminations [11] and no. 2 ring core laminations [12] in layers, each of the no. 1 [16, 25, 26] and no. 2 [17, 27, 28] partial magnetic core laminations are connected to freely rotate. Then, by repeatedly layering the no. 1 and no. 2 ring core laminations [11, 12] to the desired layering thickness, the manufacture of the layered core is completed.

[0041] The invention is not limited to the embodiment conditions described above andlayering and subsequent ring rotation may also be done by making punch outs which connect several no. 1 and no. 2 partial magnetic core laminations forming respective no. 1 and no. 2 ring core laminations in a series. Providing caulk parts all in identical positions on the no. 1 and no. 2 partial magnetic core laminations will make changing the position of the caulking part on each of the multiple laminations possible. Further, whnever depositing the no. 2 ring core laminations on the no. 1 ring core laminations and adding a load, insertion into the circular hole of the axis and caulk layering can be executed at the same time and, at the point in time when several no. 2 ring core laminations are loaded respectively on no. 1 ring core laminations, caulk layering can be strengthened by the addition of a bigger load.

[0042] In the manufacturing method of the layered core of the invention, when layering a no. 2 partial magnetic core lamination furnishing an axis inserted on one side of a magnetic pole extending inward from a partial yoke and a partial yoke lamination onto a no. 1 partial magnetic core lamination furnishing a circular hole partially opening to one side of a magnetic pole extending inward from a partial yoke and a partial yoke lamination, to connect the no. 1 and no. 2 magnetic core laminations to rotate freely, the partial yokes are formed symmetrically opposite the magnetic poles in the no. 1 and no. 2 partial magnetic core laminations and layering of the no. 1 and no. 2 ring core laminations can be simply executed. additionally, the connectors, not being constructed to form convex and concave parts on the partial yokes, can be stably formed from thin metal laminate and mobility and atability of connectors is made possible. 

1. The manufacturing method of a layered core in which several no. 1 partial magnetic core laminations which form no. 1 ring core laminations and several no. 2 partial magnetic core laminations which form no. 2 ring core laminations are punched out alternately from a metal laminate. In the manufacturing method of the layered core which repeats this layering to the desired thickness, for said no. 1 partial magnetic core laminations, a connector is formed which connects with the upper side of said no. 2 partial magnetic core laminations on one side of a partial yoke on the outer circumference and a magnetic pole which extends from the said partial yoke inwards and for said no. 2 partial magnetic core laminations, a connector is formed which connects with the lower side of said no. 1 partial magnetic core laminations on one side of a partial yoke on the outer circumference and a magnetic pole which extends from said partial yoke inwards. Moreover, said connector formed on one side of the partial yoke of said no. 1 magnetic core laminations are formed as a partially open circular hole and the connector formed on one side of the partial yoke of said no. 2 partial magnetic core laminations forms an axis which is inserted into said circular hole formed on said no. 1 partial magnetic core laminations. When several no. 2 partial magnetic core laminations are fully extracted and layered onto several previously extracted no. 1 partial magnetic core laminations, said axis are bent and inserted into said circular holes; said no. 1 partial magnetic core laminations and no. 2 partial magnetic core laminations are connected in a free rotation. 